Method for Fabricating Thermoplastic Composite Parts

ABSTRACT

A system and method for forming a composite part. The apparatus comprises a sleeve that molds a composite material. The sleeve has a first face and a second face. The second face has features to mold the composite material. The first face comprises a first inclined surface having an angle less than about 90 degrees and greater than about 0 degrees.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation in part of U.S. patent applicationSer. No. 13/673,989, filed on Nov. 9, 2012, which is a continuationapplication of U.S. patent application Ser. No. 11/584,923 filed Oct.20, 2006, now U.S. Pat. No. 8,333,858, issued Dec. 18, 2012, which is acontinuation-in-part application of U.S. patent application Ser. No.11/347,122, filed Feb. 2, 2006, now U.S. Pat. No. 7,807,005, issued Oct.5, 2010. This application is also a continuation in part of U.S. patentapplication Ser. No. 14/182,215, filed on Feb. 17, 2014, which is adivisional application of U.S. patent application Ser. No. 12/398,071,filed on Mar. 4, 2009, now U.S. Pat. No. 8,691,137, issued Apr. 8, 2014,in which the entire disclosures of all are incorporated by referenceherein.

BACKGROUND OF THE INVENTION

1. Field

The present disclosure generally relates to composite structures and, inparticular, to the fabrication of composite structures. Still moreparticularly, the present disclosure relates to a method and apparatusfor fabricating thermoplastic composite parts.

2. Background

Aircraft are being designed and manufactured with greater and greaterpercentages of composite materials. Composite materials are used inaircraft to decrease the weight of the aircraft. This decreased weightimproves performance features such as payload capacities and fuelefficiencies. Further, composite materials provide longer service lifefor various components in an aircraft.

Composite materials are long lasting, lightweight materials created bycombining two or more functional components. For example, a compositematerial may include reinforcing fibers bound in polymer resin matrix.The fibers may be unidirectional or may take the form of a woven clothor fabric. Resins used in composite materials may include thermoplasticor thermoset resins. A thermoplastic material may become soft uponheating and may harden upon cooling. A thermoplastic material may beable to be repeatedly heated and cooled. A thermoset material may becomehard after being heated to a curing temperature. In thermosetcomposites, fibers and resins are arranged and cured to form a compositematerial. Thermoset materials may not become soft upon being heatedagain.

Numerous processes exist for the fabrication of Thermoplastic composite(TPC) laminates of constant thickness and straight length. In additionto non-continuous processes such as pressing, stamping and autoclaveforming, there are continuous processes such as extrusion, pultrusion,roll forming, and compression molding. Although these latter processesare capable of producing parts in continuous lengths, they lack theability to produce parts of varying thickness that are needed forlightweight aerospace structures and other structures where weight is ofparticular importance. Moreover, the processes mentioned above are notcapable of producing parts that have curvature along their length.

There thus exists a need to provide a new method that is capable offabricating curved TPC laminates with tailored thicknesses in acontinuous process. Preferably, such a method should be a low costmethod and take advantage of automated equipment where possible.

Further, during continuous compression molding, it may be desirable tohave substantially even pressure distribution on material. Continuouscompression molding applying uneven pressure distribution on materialmay result in less than desired quality. For example, applying unevenpressure may result in a product with non-uniform thickness, porosity,or other inconsistencies. Thus, there exists a need to provide a methodand apparatus capable of providing substantially even pressuredistribution to thermoplastic laminates during continuous compressionmolding.

SUMMARY

An illustrative embodiment of the present disclosure provides anapparatus. The apparatus comprises a sleeve that molds a compositematerial. The sleeve has a first face and a second face. The second facehas features to mold the composite material. The first face comprises afirst inclined surface having an angle less than about 90 degrees andgreater than about 0 degrees.

A further illustrative embodiment of the present disclosure provides anapparatus. The apparatus comprises an inclined die having a first face,an inclined sleeve having a second face in engageable alignment with theinclined die, and a shim positioned between the first face of theinclined die and the second face of the inclined sleeve.

Another illustrative embodiment of the present disclosure provides anapparatus. The apparatus comprises a sleeve located between a continuouscompression molding die and a composite charge. The sleeve has a firstface that forms a cavity. The first face comprises a first inclinedsurface having an angle less than about 90 degrees and greater thanabout 0 degrees which conforms to a second inclined surface of thecontinuous compression molding die.

A yet further illustrative embodiment of the present disclosure providesa method. The method places a multiple ply stack relative to an inclinedsleeve such that at least a portion of the multiple ply stack contactsat least a portion of a first face of the inclined sleeve. The methodmay also feed the multiple ply stack and the inclined sleeve into acontinuous compression molding machine. The method may also lower aninclined die of the continuous compression molding machine to engage asecond face of the inclined sleeve.

Another illustrative embodiment of the present disclosure provides amethod. The method installs an inclined sleeve over an inclined die suchthat a first inclined surface of the inclined sleeve engages a secondinclined surface of the inclined die. The first inclined surface has anangle less than about 90 degrees and greater than about 0 degrees. Themethod may also place at least one shim between the inclined sleeve andthe inclined die. The method may secure the inclined sleeve to theinclined die.

The features and functions can be achieved independently in variousembodiments of the present disclosure or may be combined in yet otherembodiments in which further details can be seen with reference to thefollowing description and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The novel features believed characteristic of the illustrativeembodiments are set forth in the appended claims. The illustrativeembodiments, however, as well as a preferred mode of use, furtherobjectives and features thereof, will best be understood by reference tothe following detailed description of an illustrative embodiment of thepresent disclosure when read in conjunction with the accompanyingdrawings, wherein:

FIG. 1 is an exploded view and perspective view of a thermoplasticcomposite laminate formed in accordance with a preferred embodiment ofthe invention;

FIG. 2 is a perspective view of a conveyor table used to form a tailoredmultiplayer stack in accordance with an illustrative embodiment;

FIG. 3 is a perspective view of one example of a tailored multi-layerstack formed in FIG. 2 in accordance with an illustrative embodiment;

FIG. 4 is a view of a pre-forming zone and a consolidating zone of aconsolidation structure used to form the thermoplastic compositelaminate of FIG. 1 in accordance with an illustrative embodiment;

FIG. 5 is a perspective view of the pre-forming zone of theconsolidation structure of FIG. 4 in accordance with an illustrativeembodiment;

FIG. 6 is a logic flow diagram describing the preferred method forforming the thermoplastic composite laminate of FIG. 1 in accordancewith FIGS. 2-5 in accordance with an illustrative embodiment;

FIGS. 7A-7F are perspective views representing examples of curved,thermoplastic composite laminate parts formed in accordance with themethod of the invention;

FIG. 8 is a perspective view of a tailored, multilayer stack ofthermoplastic composite material, with three curved part blanks cut fromthe stack in accordance with an illustrative embodiment;

FIG. 9 is a perspective view of tooling used to form the curvedthermoplastic composite parts in accordance with the method of theinvention;

FIG. 10 is a perspective view of a curved tool used to impart featuresto the curved thermoplastic composite part in accordance with anillustrative embodiment;

FIG. 11 is a bottom view of the tool shown in FIG. 10 in accordance withan illustrative embodiment;

FIG. 12 is a fragmentary, cross sectional view showing a portion of acurve composite part captured between two portions of a tool inaccordance with an illustrative embodiment;

FIG. 13 is an exploded, cross sectional view of a thermoplasticcomposite I-section beam, shown in operative relationship to tooling andmachine press dies used to compact the laminate plies in accordance withan illustrative embodiment;

FIG. 14 is a perspective view of a pre-forming structure and a portionof a compaction press used in the method to produce curved compositeparts in accordance with an illustrative embodiment;

FIG. 15 is a view similar to FIG. 14 but showing the opposite side ofthe pre-forming structure and press in accordance with an illustrativeembodiment;

FIG. 16 is a sectional view through the press, showing the diescompressing the preformed part using the consolidation tooling inaccordance with an illustrative embodiment;

FIG. 17 is a fragmentary view of a section of the press, showing acurved die in relation to tooling sleeves for producing a part having aconstant curvature in accordance with an illustrative embodiment;

FIG. 18 is view similar to FIG. 17 but showing tooling sleeves forproducing a part having a non-uniform curvature in accordance with anillustrative embodiment;

FIG. 19 is an illustration of an isometric view of an inclined sleeve inaccordance with an illustrative embodiment;

FIG. 20 is an illustration of a front view of an inclined sleeve inaccordance with an illustrative embodiment;

FIG. 21 is an illustration of one example of an isometric view of aninclined sleeve, tooling, and composite material in accordance with anillustrative embodiment;

FIG. 22 is an illustration of another example of an isometric view of aninclined sleeve, tooling, and composite material in accordance with anillustrative embodiment;

FIG. 23 is an illustration of a further example of an isometric view ofan inclined sleeve, tooling, and composite material in accordance withan illustrative embodiment;

FIG. 24 is an illustration of another example of an isometric view of aninclined sleeve, tooling, and composite material in accordance with anillustrative embodiment;

FIG. 25 is an illustration of a cross-sectional view of an inclinedsleeve in a continuous compression molding machine in accordance with anillustrative embodiment;

FIG. 26 is an illustration of a front view of an inclined sleeve in acontinuous compression molding machine in accordance with anillustrative embodiment;

FIG. 27 is an illustration of an isometric view of an inclined sleeve inaccordance with an illustrative embodiment;

FIG. 28 is an illustration of a front view of an inclined sleeve inaccordance with an illustrative embodiment;

FIG. 29 is an illustration of a flowchart of a process for forming acomposite part in accordance with an illustrative embodiment;

FIG. 30 is an illustration of a flowchart of a process for forming acomposite part in accordance with an illustrative embodiment;

FIG. 31 is an illustration of an aircraft in accordance with anillustrative embodiment;

FIG. 32 is an illustration of a block diagram of an aircraftmanufacturing and service method in accordance with an illustrativeembodiment; and

FIG. 33 is an illustration of a block diagram of an aircraft in which anillustrative embodiment may be implemented.

DETAILED DESCRIPTION OF THE INVENTION

The invention provides a novel fabrication method of forming athermoplastic composite (“TPC”) laminate material with tailored andvarying thicknesses in a continuous process. The invention findsapplicable uses in a wide variety of potential applications, includingfor example, in the aerospace industry. The preferred method of theinvention is ideally suited for forming thermoplastic compositestiffened members in the supporting framework of an aircraft fuselage.Potential examples of thermoplastic composite stiffened members includebut are not limited to fuselage skins, wing skins, control surfaces,door panels and access panels. Stiffening members include but are notlimited to keel beams, floor beams, and deck beams. For illustrativepurposes only, the invention will initially be described in reference toforming a thermoplastic composite floor beam 20 for use in a commercialaircraft fuselage. However, while an I-section is shown, other stiffenedmember geometries such as Z-section, U-section, T-section, etc. willalso be later described, including those having curvature along theirlength.

Referring now to FIG. 1, a thermoplastic composite laminate, here athermoplastic composite laminate floor beam 20 having tailored andvarying thickness regions t1 and t2 is illustrated as having a webregion 22 coupled at either end to a respective pair of cap regions 24.The web region 22 and pair of cap regions 24 are formed as a singleintegrated laminate structure by consolidating a pair of non-uniformthickness tacked multi-layer ply sheet stacks 76 with a pair ofthermoplastic composite filler nuggets 26 and further with a pair ofuniform thickness tacked multi-layer ply sheet stacks 74. Although sheetstack 76 is shown as comprising 2 plies, it is to be understood thateither of the sheet stacks 74 and 76 may include any number of plies,depending on the application. It will also be understood that capregions 24, which are shown in FIG. 1 as having a uniform thickness andone ply, may similarly be provided with regions of varying thicknessesand/or a plurality of plies.

In alternative versions (not shown), a thermoplastic composite laminatesuch as the floor beam 20 may alternatively be formed by consolidatingone or more uniform or non-uniform tacked multi-layer ply sheets 74,76with either one or more single ply (shown as 32 in FIGS. 2 and 3) of athermoplastic composite material 30, one or more partial ply (shown as34 in FIG. 3) of a thermoplastic material 30, or one or more uniform ornon-uniform thickness tacked multi-layer tacked stacks 74, 76, and anycombination thereof, in a similar method to that described herein.Further, one or more filler nuggets 26 may also be used in combinationthereof to form further alternative versions of the thermoplasticcomposite laminate 20. The method for forming the thermoplasticcomposite floor beam 20 as shown in FIG. 1 is described below in moredetail in conjunction with FIGS. 2-6.

The thermoplastic materials 30 used in plies 32, 34 includethermoplastic matrix polymers (shown as 40 in FIG. 3) such aspolyetheretherketone (“PEEK”), polyetherketoneketone (“PEKK”),polyphenylsulfone (“PPS”), polyetherimide (“PEI”) preferably reinforcedwith a fibrous component (shown as 38 in FIG. 3) such as glass (s-typeor e-type) or carbon fiber. The fibers 38 within each ply 32, 34 of thethermoplastic materials 30 may be oriented in a unidirectional ornon-uniform arrangement, depending upon the particular application. Asone of ordinary skill recognizes, the relative types, thicknesses,amounts of fibers 38 within the matrix resin 40, as well as the type ofmatrix resin utilized in each ply 32, 34 may vary greatly, based onnumerous factors, including cost and the ultimate desired physical andmechanical properties of the thermoplastic laminate composite 20.Further, the relative orientation of the unidirectional fibers in oneply 32, 34 relative to another ply 32, 34 may also affect the mechanicalproperties of the thermoplastic composite laminate 20.

The nuggets 26 are preferably formed from a thermoplastic material 37that is compatible with the thermoplastic material 30 via extrusion orother well-known forming process. Preferably the matrix resincomposition 42 of the nuggets 26 is the same as the matrix resincomposition 40 of the materials 30. In addition, the filler nuggets 26may utilize fibers 44 similar to the fibers 38 contained within thethermoplastic material 30.

Referring now to the logic flow diagram (FIG. 6) and the processingdiagrams (FIGS. 2-5), the method for forming the TPC laminate floor beam20 of FIG. 1 begins in Step 150 by providing preformed plies 32, 34 ofthe thermoplastic materials 30 and preformed filler nuggets 26 eachretained on roller 46 or other retention devices. Next, in Step 160,multiple plies 32, 34 of the thermoplastic materials 30 are stacked in adesired configuration to form either a non-uniform thickness or uniformthickness untacked multi-layer ply sheet stack 58 or 60 using either ahand lay-up or automated process.

In the automated process, as shown in FIG. 2, a plurality of plies 32 or34 (FIG. 3) of the thermoplastic material 30 are unrolled from rollers46 onto a conveyor table 48 to form a collated multi-layer non-uniformthickness or uniform thickness multi-layer ply stack 58 or 60. Therollers 46 may be situated at one end, or along the sides of theconveyor table 48 to lay respective ply layers 32, 34 at a particularorientation with respect to another adjacent layer 32, 34. Thus, forexample, a lower layer of a full ply 32 may be laid havingunidirectional fibers 38 extending in one direction, while the nextrespective upper full ply 32 may have unidirectional fibers 38 laid inanother direction (for example, at 45 or 90 degrees relative to theunderlying ply 32). A laser projector 56 located above the conveyortable 48 ensures proper location of the local or partial plies 34 and/orpockets 36 relative to the full plies 32.

An example of an untacked, non-uniform thickness multi-layer sheet stack58 made according to the process of FIG. 2 is shown in FIG. 3, whichshows various full and partial plies 32, 34 and further showing pockets36 created between plies 32, 34. Moreover, FIG. 3 shows partial plies62, 64 having unidirectional fibers 38 laid in a 90-degree relativeorientation with respect to one another, here showing partial ply 62laid in a first orientation (fibers 38 extending from front 66 to back68), while partial ply 64 is laid in a different orientation (fibers 38extending from side 70 to side 72). Of course, while not shown, pliesmay have fibers 38 at other relative orientations to one another,ranging from perpendicular to one another (i.e. a 0/90 arrangement) toparallel with one another (i.e. a 0/0 arrangement) and every conceivableangle therebetween (including, for example a 0/30 orientation, a 0/60,0, 45, 90 orientation etc.).

Next, in Step 170, some or all of various plies 32, 34 of the untackedstacks 58, 60 formed in FIG. 2 may be tacked together at variouspredetermined locations to form either a uniform or non-uniformthickness tacked multi-layer ply sheet stack 74, 76. Preferably, thestacks 58, 60 are tacked together using a soldering iron or ultrasonicwelder (not shown) to form the respective stack 74, 76, although otherdevices used to couple together various plies 32, 34 of thermoplasticmaterials known to those of ordinary skill are also specificallycontemplated. The amount and location of tacking among the plies 32, 34is dependent upon numerous factors, including but not limited to thenumber and location of the various plies 32, 34 and pockets 64.Moreover, the amount of tacking should be sufficient to form asubstantially integrated tacked stack 74, 76 that can be transported asa single part. In Step 175, the tacked stacks 74, 76 may then be cutinto smaller pieces, or are ready for use in forming the thermoplasticcomposite laminates such as floor beam 20 of FIG. 1.

Next, in Step 180, a combination of at least one uniform or non-uniformthickness tacked stack 74, 76, and at least one of either a non-uniformthickness tacked stack 76, a uniform thickness tacked stack 74, or asingle ply 32, and optionally at least one filler nugget 26 ofthermoplastic material 30, 37 are fused together in a consolidationstructure 78 to form a single integrated thermoplastic compositelaminate such as floor beam 20. One preferred consolidation structure 78specifically designed to form the thermoplastic composite laminate floorbeam 20 of FIG. 1 is illustrated in FIGS. 4 and 5 below.

Referring now to FIGS. 4 and 5, the consolidation structure 78 mayinclude a pre-forming zone 80 and a consolidation zone 82. In theperforming zone 80, a combination of at least one uniform or non-uniformthickness tacked stack 74, 76, optionally at least one filler nugget 26,and at least one of either a non-uniform thickness tacked stack 76, auniform thickness tacked stack 74, or a single ply 32, FIGS. 2 and 3, ofthermoplastic material are loaded in their proper orientations in acontinuous process and preformed to the desired shape at an elevatedtemperature to form the preformed part 84. The preformed part 84 thenexits the performing zone 80 and enters the consolidation zone 82,wherein it is consolidated to form a single, integrated thermoplasticcomposite laminate such as floor beam 20 as described in FIG. 1 above.The elevated temperature used in performing the part should besufficiently high to cause softening of the tacked stacks 74, 76 or thesingle ply 32 so that the layers may be bent during the performingprocess. However, the elevated temperature should be below a temperatureat which the polymeric component of the matrix resin 40, 42 has theconsistency of a viscous liquid.

Referring now to FIG. 5, the pre-forming zone 80 of the consolidationstructure 78 includes a pair of U-shaped tooling channels 86 having acentral portion 88 separated by a gap 90 and a pair of sidetooling sheetmembers 92. Sheet members 92 may also be called mandrels 92. Preferably,the channels 86 and side-tooling sheet members 92 are formed ofmaterials such as stainless steel and the like, that are capable ofhandling repetitious, high-heat cycles.

A first pair 94 of tacked stacks 74 or 76 is introduced between therespective central portions 88 and within the gap 90 of the U-shapedchannels 86. At the same time, an optional filler nugget 26 and eitherthe additional tacked stack 74 or 76 or ply 32, are introduced alongeach flange 96 of the first pair 94 and within the respectiveside-tooling member 92. For the purposes of description in the followingparagraphs with respect to the illustrations of FIGS. 4 and 5, thenon-uniform thickness tacked stack 76 is shown as the first pair 94introduced within the gap 90. The uniform thickness tacked stack 74 isshown being introduced at a position between the outer portion 98 of theU-shaped channels 86 and respective side-tooling member 92. Further, theply layer 32 is not depicted in this description. While not shown, theU-shaped channels 86 include ramps and other features designed to matchthe laminate thickness variations (corresponding to t1 and t2 in FIG. 1)of the particular material (here the first pair 94 of non-uniform tackedstacks 76).

As the tacked stacks 74, 76 and nuggets 26 move through the performingzone 80 towards the consolidation zone 82, the flanges 96 of the firstpair 94 of non-uniform thickness tacked stacks 76 on either side of theu-shaped channel 86 are bent outwardly under heat and pressure away fromeach other towards the respective outer portions 98 of the U-shapedchannel 86. The flanges 96 are therefore coupled flat against the innerside of the uniform or non-uniform thickness tacked stacks 76, with thenuggets 26 located between the flanges 96 and the respective inner endof the uniform or non-uniform thickness tacked stacks 76. The heatwithin the pre-forming zone 80 is elevated sufficiently to allowdeformation of the flanges 96 of the non-uniform thickness tacked stacks76, but is below the temperature in which the polymeric component of thematrix resin 40, 42 of the respective stacks 74, 76 and nuggets 26 hasthe consistency of a viscous liquid. Bending of the flanges 96 isinitiated by pressure applied to the flange 96 by external formingdevices such as rollers (not shown). The side-tooling sheet members 92squeeze the tacked stack 74 inwardly against the flange 96, causingadditional pressure to be applied to the flange 96 which aids in bendingthe flange 96. The preformed part 84 is then ready to move to theconsolidation zone 82.

As best shown in FIG. 4, the preformed part 84 enters a separate orconnected consolidating structure 102 within consolidation zone 82 onguide roller 105. The consolidating structure 102 includes a pluralityof standardized tooling dies generally indicated at 104 that areindividually mated with the outer surfaces of the U-shaped channels 86and side-tooling sheet members 92. Additional details of the toolingdies 104 will be discussed later with reference to FIGS. 13 and 16. Thiscommonality of the surfaces between the standardized dies 104 of theconsolidating structure 102 and the outer surfaces of the channels 86and sheet members 92 eliminates the need for part-specific, costlymatched dies as well as eliminates start up times between differentpreformed parts having different ply configurations.

The consolidating structure 102 has a pulsating structure 106 thatincrementally moves the preformed part 84 forward within theconsolidation zone 82 and away from the pre-forming zone 80. As the part84 moves forward, the part first enters a heating zone 108 that heatsthe part to a temperature which allows the free flow of the polymericcomponent of the matrix resin 40, 42 of the stacks 74, 76 and nuggets26. Next, the part 84 moves forward to a pressing zone 112, whereinstandardized dies 104 are brought down collectively or individually at apredefined force (pressure) sufficient to consolidate (i.e. allow freeflow of the matrix resin) the various plies 32, 34 of the tacked stacks74, 76 and nuggets 26 into its desired shape and thickness, here formingthe web region 22 and pair of cap regions 24 of the floor beam 20. Eachdie 104 is formed having a plurality of different temperature zones withinsulators. The dies 104 do not actually contact the part 84, butcontact the outer surfaces of the U-shaped channels 86 and sidetoolingsheet members 92 opposite the part 84. Thus, the respective innersurfaces of the channels 86, 92 compress against the portion of the part84. The compression may occur wherein all of the dies 104 compress inone independent yet coordinated step. The dies 104 are opened, and thepart 84 is advanced within the consolidating zone 102 away from thepre-forming zone 80. The dies 104 are then closed again, allowing aportion of the part 84 to be compressed under force within a differenttemperature zone. The process is repeated for each temperature zone ofthe die 104 as the part 84 is incrementally advanced along the guiderollers 105 towards the cooling zone 114.

The formed and shaped part 84 then enters a cooling zone 114, which isseparated from the pressing zone 112, wherein the temperature is broughtbelow the free flowing temperature of the matrix resin 40, 42, therebycausing the fused or consolidated part to harden to its ultimate pressedshape 116. The pressed part 116 then exits the consolidating structure102, wherein the side sheet members 92 are re-rolled onto rollers 120 asscrap. While not shown, the consolidating structure 102 may haveadditional parts or devices that can introduce shapes or features intothe pressed shape 116.

One preferred consolidating zone structure 102 that may be utilized isthe so-called continuous compression molding (“CCM”) process asdescribed in German Patent Application Publication No. 4017978,published on Sep. 30, 1993, and herein incorporated by reference.However, other molding processes known to those of ordinary skill in theart are specifically contemplated by the invention, including but notlimited to pultrusion or roll forming.

Next, in Step 190, the pressed part 116 is trimmed or otherwisepost-processed to its desired final shape to form the thermoplasticcomposite laminate 20. In Step 200, the laminate 20 is inspectedvisually, preferably using ultrasonic non-destructive inspectiontechniques, or by other means to confirm that the laminate 20 iscorrectly shaped and does not contain any visual or other defects. Afterinspection, in Step 210, the laminate 20 such as the thermoplasticcomposite floor beam 20 may be installed onto its assembly. In the caseof the floor beam 20, it is introduced within an aircraft fuselage.

While the invention is described in terms of forming a thermoplasticcomposite floor beam 20 having essentially an I-beam shape, otherpotential shapes are specifically contemplated by the invention. Thisincludes thermoplastic composite laminates having an L-shape, a C-shape,a T-shape, or even a flat panel shape in which thickness transitions mayoccur in any section of the part. These alternatively shaped laminates,or even other forms of the floor beam 20, are formed by consolidatingone or more uniform or non-uniform tacked multi-layer ply sheets 74, 76with either one or more plies 32 of a thermoplastic composite material30, one or more partial plies 34 of a thermoplastic material 30, or oneor more uniform or non-uniform thickness tacked multi-layer tackedstacks 74, 76, and any combination thereof, in a similar method to thatdescribed herein. Further, one or more filler nuggets 26 may also beused to form additional alternative versions of the thermoplasticcomposite laminates 20. To accomplish any of these alternative preferredvariations, modifications to the tooling within the pre-forming zone 80is necessary so as to match the desired thickness variations for the TPClaminate 20. For example, the U-shaped tool 86 of FIG. 5 is specific forforming I-beams such as floor beam 20 of FIG. 1, an alternatively shapedtool 86 having gaps 90 is used in forming C-shaped laminates, L-shapedlaminates or flat beams having a taper between respective ply layers.Similar to the U-shaped tool 86, these alternative tools include regionsnot contacting the stacks 74, 76 that are matched to the standardizeddies 104 within the consolidating zone 102.

While the invention is ideally suited for forming thermoplasticcomposite laminates, by using a modified single-step consolidation zone,thermosetting laminate composites can also be formed. In this modifiedversion of the consolidation process, the heating and pressing zonesachieve a temperature above the reaction or curing temperature of thematrix resin to form a thermosetting part. Accordingly, the singlepressing process achieves a part having its ultimate desired shapewithout subsequent pressing steps.

The invention provides an innovative method to fabricate complexthermoplastic composite laminates with tailored and varying thickness ina continuous process. This innovative process utilizes automatedequipment or hand lay-up to collate parts or components into amulti-layer stack. Each stack contains all plies, including ply build-upareas, tacked in the proper location to maintain orientation andlocation. The consolidation structure utilizes a two-stage method forforming the composite laminates from the multi-layer stacks and containsall necessary part features to achieve this result. The tooling, such asthe U-shaped tool 86 in the pre-forming zone 80 is created with anappropriate shape to create the desired thickness variations in theformed TPC laminates 20 and is further designed to mate withstandardized dies with the consolidation zone 82

The composite part formed by the above method may find use in a widevariety of applications, including, for example, automotive andaerospace applications. One example of a composite part formed inaccordance with the invention is ideally suited for use as structuralstiffened members, including thermoplastic composite laminate floorbeams 20, in a commercial aircraft.

Referring now to FIGS. 7-15, an alternate embodiment of the inventionmay be used to manufacture thermoplastic laminate parts that are bothcurved and have tailored and/or varying thickness along their length.Curved laminates can be produced in which the curvature is eitherconstant (circular) or variable along the length of the laminate part.As in the case of the embodiment previously described, the curvedthermoplastic laminate part may include tailored areas and areas ofvarying thickness achieved by adding partial or local plies, or areascontaining pockets. “Tailored” or “tailoring” refers to the profile ofthe part surface, wherein the selective addition or reduction of pliesin specific areas of the part can be used to achieve a desired surfaceprofile after the plies are consolidated during the compaction process.Curved parts produced by this embodiment of the method may be used in avariety of applications such as frames, rings, formers and structuralaircraft stiffened members or fuselage skins, wing skins, door panelsand access panels, keel beams, floor beams, and deck beams. The curvedparts can be produced with a variety of cross sections, such as thoseshown in FIGS. 7A-7F. A fabricated part 212 having an I-section is shownin FIG. 7A while a part 214 having a U-section is shown in FIG. 7B. AnL-section part 216

shown in FIG. 7C and a T-section part is shown in FIG. 7D. A part 220having a Z-section as shown in FIG. 7E and a part 222 having a simplerectangular section is shown in FIG. 7F. The parts shown in FIGS. 7A-7Fmay have either constant or variable curvature as previously mentioned,and may include areas of varying or tailored thickness at one or morepoints along their lengths.

The preliminary steps in fabricating curved thermoplastic laminate partsin accordance with this embodiment of the method are similar to thosepreviously described. A plurality of plies of thermoplastic material aredeposited onto a conveyor table to form a collated, multi-layernon-uniform thickness or uniform thickness multi-ply stack, aspreviously described in connection with FIG. 2. The resulting,multi-layer stack is thus similar to the stack 58 shown in FIG. 3 whichincludes full and partial plies 32, 34 as well as pockets 36 createdbetween plies 32, 34. Partial plies 62, 64 may also be included whichhave unidirectional fibers 38 arranged at alternating angles relative tothe direction of orientation of the fibers. As previously described, thesheets in the multi-layer stack 58 are tacked together using a solderingiron or other heating device (not shown) so that the plies are held infixed relationship to each other. A collated, tacked stack 224 producedby the method previously described is shown in FIG. 8.

The next step in the method for producing the curved composite partscomprises cutting individual part ply stacks or part blanks 226 from thecollated stack 224. This cutting operation may be performed, forexample, by a water jet cutter (not shown) operating under computercontrol which produces cut blanks 226 having an outer profile generallycorresponding to the desired part curvature. As previously indicated,this curvature may be constant or may vary along the length of the partblank 226.

The part blanks 226 are fed along with a later described set ofconsolidation tooling 235 to a pre-forming station 275 (FIGS. 14 and 15)in a manner generally similar to that described previously with respectto producing non-curved composite parts. In the case of the presentembodiment however, the consolidation tooling 235 and the blanks 226move through a curved path as they are fed into the pre-forming station275.

The consolidation tooling 235 is shown in FIG. 9 and comprises curvedinner and outer tooling sleeves 228, 230 as well as upper and lowertooling sleeves 232, 234. The upper and lower tooling sleeves 232, 234each possess a curvature corresponding to that of the blanks 226, whilethe inner and outer tooling sleeves 228, 230 may be either similarlycurved, or flexible so as to conform to the curvature of the part blank226 during the pre-forming process. In the example illustrated in FIGS.9, 14 and 15, the tooling sleeves 228-234 are configured to produce theZ-section part 220 shown in FIG. 7E. Although not specifically shown inthe drawings, the part-side surfaces of the tooling sleeves 228-234contain tooling features that produce mirror image features in the part,such as varying thicknesses, varying curvature, pockets, etc.

Referring now particularly to FIGS. 14 and 15, the upper and lowertooling sleeves 232, 234 are assembled around the part blank 226 beforethe blank is fed in a curved path 280 into the pre-forming station 275which includes a plurality of forming devices 268 and a set of guides270. The part blank 226 can be seen to include a flat tacked stack 262that comprises the web 220 a and cap 220 b (FIG. 7E) of the Z-sectionpart 220, and a set of buildup plies 264 which form a localreinforcement of the beam web 220 a.

As the sandwiched assembly comprising the part blank 226 and the toolingsleeves 232, 234 is fed into pre-forming station 275, the inner andouter tooling sleeves 228, 230 are fed into contact with the sandwichedassembly. Forming devices 268 function to deform edge portions of ablank 226 against flanges 265 on tooling sleeves 232, 234, therebypre-forming the caps 220 b of the Z-section part 220. Simultaneously,additional cap reinforcement plies 266 are fed between the formingdevices 268 and the tooling flange 265. Guides 270 bring the inner andouter tooling sleeves 228, 230 into contact with the edges of the blank226 which form the caps 220 b. The preformed blank 226 along with thetooling sleeves 235 continue their movement in the curve path 280through a curved press 284 such as a CCM machine which contains diesthat impose force on the consolidation tooling 235. This force resultsin compaction and consolidation of the plies of the preformed part.Although not specifically shown in the drawings, heaters or ovens areprovided as necessary to heat the part blank 226 to a temperature atwhich the polymeric component of the matrix resin in the part blank 226has the consistency of a viscous liquid. Heating of the part blank 226in this manner facilitates ply consolidation. In some cases, pre-heatingof the part blank 226 may also be required to facilitate the pre-formingprocess. The need for pre-heating of the part blank 226 can depend on anumber of factors, such as the number of plies, ply orientation, thetype of material, the shape being preformed, etc.

The press 284 is essentially similar to that previously described inconnection with FIG. 4. However unlike the press shown in FIG. 4, thedies used in press 284 will comprise some degree of curvature toaccommodate the curved, preformed part 226. One such die 286 is shown inFIG. 17, where it can be seen that the inner face 296 of the die 286 hasa curvature that matches the curvature of the flange 265 on the uppertooling sleeve 232. Die 286 moves inwardly in the direction of thearrows 288, into contact with the flange 265 during the compactionprocess, and in opposition to another curved die (not shown) which movesinto contact with the inner tooling sleeve 228. The amount of curvatureof the dies used in press 284 will depend, in part, on the shape of thecurved part being produced and the shape of the tooling sleevesnecessary for fabrication of the features in the part. The outer face298 of the die 286 may be curved as shown in the FIG. 17, or may beflat. The preformed part is moved in the curved path 280, incrementallythrough the press 284. As the part movement is paused at eachincremental step, the press dies impose heat and force on the toolingsleeves 235, resulting in consolidation of a section of the plies thatlie beneath the dies.

As previously indicated, the laminated part may have a varying, ratherthan a constant curvature, along its length, and in this connectionattention is directed to FIG. 18. A die 286 used to compact a curvedpreformed part 292 has a constant curved inner face 296 which engagesthe outer face 300 of a tooling sleeve 290. The outer face 300 oftooling sleeve 290 has a constant curvature, matching the curvature ofthe inner face 296 of the die 286, but has an inner face 302 that iscurved with a radius different than that of the outer face 300 of thetooling sleeve 290, resulting in a part 292 having a non-constant outerradius.

Another example of a curved thermoplastic laminate part 236 is shown inFIGS. 10 and 11 wherein the part has curvature over its length and has abody 238 which is U-shaped in cross section. The body 238 has a pair ofsloped ramps 240 which form transitions in the thickness of the body 238so that the part 236 has 3 sections of different thicknesses along itslength. In addition, the top side of the body 238 is provided with apocket or depression 242 representing an area of reduced thickness inthe part 236. The differing thicknesses of the body 238 are representedby t₁, t₂, t₃, while the thickness of the pocket 244 is represented byt₄. Although part 236 possesses constant inner and outer curvatures, itis to be understood that the curvature may vary along the length of thepart 236.

FIG. 12 shows a portion of the part 236 held within tooling sleeves 246,248 for consolidating the part plies. The part plies 236 can be seen tohave a ply buildup area 252 which effectively increases the thickness ofthe body 238, and results in the slope 240. The tooling sleeves includea release coated metal shim 246 and an outer consolidation tool portion248 having a ramp for forming the slope 240. As viewed in FIG. 12, thetop side of the tooling sleeve 248 is flat so as to be engageable with auniversal die, such as any of the dies 256 shown in FIG. 13.

FIG. 13 shows another example of a curved part 212 fabricated inaccordance with the method of the invention. Part 212 comprises a curvedbeam having an I-shaped cross section. Conventional machine dies 256 canbe used to consolidate parts that have both curvature and varyingthickness along their length. In this example, the tooling sleevescomprises a pair of flat metal sheets or shims 260 and a pair of toolingsleeves 258 that are generally U-shaped in cross section. The flatsheets 260 assist in forming the caps of the part 212 while sleeves 258function to form portions of the cap as well as the web of the part 212.The faces of the sleeves 258 that face the part 212 may have toolingfeatures such as raised areas or ramps that impart mirror image featuresonto the part 212. Although not specifically shown in FIG. 13, thesheets 260 and tooling sleeves 258 may be curved along their length inorder to form a part 212 that is also curved.

The invention provides an innovative method to fabricate curvedthermoplastic composite laminates with tailored and varying thicknessesin a continuous process. This innovative process utilizes automatedequipment or hand lay-up to collate parts or components into amulti-layer stack. Each stack contains all plies, including ply build-upareas, tacked in the proper location to maintain orientation andlocation. The consolidation tooling contains all necessary part featuresand is coordinated to the customized multiple 2 ply stacks to form asingle integrated composite laminate potentially having areas ofdiffering thicknesses from these multiple ply stacks. The composite partformed by the above method may find use in a wide variety ofapplications, including, for example, automotive and aerospaceapplications. One example of a composite part formed in accordance withthe invention is ideally suited for use as structural stiffened membersin a commercial aircraft.

In accordance with one aspect of the invention, a method is provided formanufacturing a curved thermoplastic laminate part having tailored andvarying thickness. The method comprises the steps of: forming a multipleply stack of thermoplastic material having non-uniform thickness;cutting a curved blank from the stack; feeding the curved blank in acurved path through a pre-forming structure to produce a preformed part;feeding the preformed part in a curved path through a press; and,pressing the preformed part to compact the plies. The plies in the stackare tacked together by local melting of the thermoplastic resin so thatthe plies are held in fixed relationship to each other. A plurality ofpart blanks may be cut from each stack of material. Each of the blanksis fed through a pre-forming structure where certain features of thepart are preformed before the laminate plies are compacted. Tailored andvarying thickness features of the part are formed using curved toolswhich are placed over the preformed part and fed along with the partinto the press. Pressing the curved tool against the preformed partwithin the press imparts the surface features of the tool into the partas the plies are compacted.

In accordance with another aspect of the invention, a method is providedfor manufacturing a curved thermoplastic laminate part having tailoredand varying thickness in a continuous process. The method comprises thesteps of: feeding a multi-ply thermoplastic laminate blank in a curvedpath through a pre-forming structure to produce a curved preformed part;feeding the curved preformed part in a curved path through a press; and,pressing the preformed part to compact the plies and impart featuresinto the part defining the tailored and varying thickness. The methodmay further comprise the steps of forming a multi-ply stack ofthermoplastic material having non-uniform thickness, and, cutting thecurved blank from the multi-ply stack. The plies in the stack are tackedtogether so as to hold the plies in fixed relationship to each other asthe laminate blank is fed through the pre-forming structure. The curved,preformed part is heated to the melting point of the thermoplastic resinmatrix, and then moved through the press in incremental steps so thatthe press compacts a section of the part after each incremental step.

In accordance with still another aspect of the invention, a method isprovided for manufacturing a curved thermoplastic laminate part havingtailored and varying thickness features. The method comprises the stepsof: forming a curved, multi-ply thermoplastic laminate blank; producinga curved preformed part by deforming portions of the blank; bringing acurved tool into contact with the curved preformed part; feeding thecurved preformed part along with the curved tool in a curved paththrough a compaction press; and, pressing the curved tool and the curvedpreformed part together to compact the laminate plies and form thetailored and varying thickness. The method may further comprise thesteps of forming a multi-ply stack of thermoplastic material havingnon-uniform thickness; and, cutting the curved blank from the stack ofmaterial. A soldering iron or the like may be used to tack the pliestogether so as to hold the plies in fixed relationship to each otherwhile the blank is being deformed into a preformed part.

Turning now to FIG. 19, an illustration of an isometric view of aninclined sleeve is depicted in accordance with an illustrativeembodiment. Inclined sleeve 1900 may also be referred to as a toolingchannel. Inclined sleeve 1900 may be used with associated toolingsimilar to U-shaped tooling channels 86 of FIG. 1.

Inclined sleeve 1900 may have first face 1902 and second face 1904.Second face 1904 may have features to mold a composite material. Firstface 1902 may have first inclined surface 1906, second inclined surface1908, and substantially planar surface 1910. As depicted, substantiallyplanar surface 1910 may be positioned between first inclined surface1906 and second inclined surface 1908.

First face 1902 may form cavity 1912. Cavity 1912 may receive aninclined die (not depicted). The inclined die may have its ownrespective inclined surfaces. First inclined surface 1906 maysubstantially conform to a portion of the inclined die. Second inclinedsurface 1908 may substantially conform to a second portion of theinclined die.

To form a composite material, inclined sleeve 1900 may be positionedbetween the inclined die and the composite material. In theseillustrative examples, first face 1902 may engage the inclined die whilesecond face 1904 may contact the composite material.

Turning now to FIG. 20, an illustration of a front view of an inclinedsleeve is depicted in accordance with an illustrative embodiment. View2000 may be a view of inclined sleeve 1900 from direction 20-20 of FIG.19. First inclined surface 1906 may be positioned at angle 2002 relativeto substantially planar surface 1910. Second incline surface 1908 may bepositioned at angle 2004 relative to substantially planar surface 1910.As depicted, angle 2002 and angle 2004 are about the same. However, insome illustrative examples, angle 2002 and angle 2004 may be differentfrom each other.

As depicted, angle 2002 and angle 2004 may be about 75 degrees. However,angle 2002 and angle 2004 may be any desirable angle within greater thanabout 0 degrees and less than about 90 degrees. Angle 2002 may beselected based on at least one of an angle of an inclined surface of aninclined die, manufacturing tolerances, material properties of thematerial of inclined sleeve 1900, or other desirable information. Forexample, angle 2002 may be selected such that undesirable heat transferproperties due to the thickness of material of inclined sleeve 1900 arereduced. For example, reducing angle 2002 may increase the thickness ofmaterial of inclined sleeve 1900. As used herein, reducing angle 2002may cause angle 2002 to approach 0 degrees. With increased thickness ofinclined sleeve 1900, inclined sleeve 1900 may take longer to heat andcool. As a result, heat transfer properties may become more undesirableas angle 2002 decreases.

As another example, angle 2002 may be selected such that the weight ofinclined sleeve 1900 is not undesirably high. For example, reducingangle 2002 may increase the thickness of material of inclined sleeve1900. Increasing the thickness of the material of inclined sleeve 1900may also increase the weight of inclined sleeve 1900.

Angle 2004 may be selected based on at least one of an angle of aninclined surface of an inclined die, manufacturing tolerances, materialproperties of the material of inclined sleeve 1900, or other desirableinformation. For example, angle 2004 may be selected such thatundesirable heat transfer properties due to the thickness of material ofinclined sleeve 1900 are reduced. For example, reducing angle 2004 mayincrease the thickness of material of inclined sleeve 1900. As usedherein, reducing angle 2004 may cause angle 2004 to approach 0 degrees.With increased thickness of inclined sleeve 1900, inclined sleeve 1900may take longer to heat and cool. As a result, heat transfer propertiesmay become more undesirable as angle 2004 decreases. As another example,angle 2004 may be selected such that the weight of inclined sleeve 1900is not undesirably high. For example, reducing angle 2004 may increasethe thickness of material of inclined sleeve 1900. Increasing thethickness of the material of inclined sleeve 1900 may also increase theweight of inclined sleeve 1900.

Turning now to FIG. 21, an illustration of one example of an isometricview of an inclined sleeve, tooling, and composite material is depictedin accordance with an illustrative embodiment. As depicted, inclinedsleeve 2100 may be used as a U-shaped tooling channel 86 of FIG. 1.Inclined sleeve 2100 may be used in a continuous compression moldingmachine to shape composite material 2102.

Inclined sleeve 2100 may have first face 2104 and second face 2106.Second face 2106 may have features to mold composite material 2102.First face 2104 may have first inclined surface 2108, second inclinedsurface 2110, and substantially planar surface 2112. As depicted,substantially planar surface 2112 may be positioned between firstinclined surface 2108 and second inclined surface 2110.

First face 2104 may form cavity 2114. Cavity 2114 may receive aninclined die (not depicted). As depicted, composite material 2102 may bepositioned between inclined sleeve 2100 and base 2116. Inclined sleeve2100, composite material 2102, and base 2116 may all move in direction2118 towards a continuous compression molding machine (not depicted). Asinclined sleeve 2100, composite material 2102, and base 2116 may allmove in direction 2118, composite material 2102 may be formed to contactside 2120 and side 2122 of second face 2106. Specifically, surface 2123may be formed to second face 2106. Side tooling member 2124 and sidetooling member 2126 may be positioned relative to composite material2102 and inclined sleeve 2100. Each of inclined sleeve 2100, compositematerial 2102, base 2116, side tooling member 2124, and side toolingmember 2126 may move in direction 2118 towards an inclined die of thecontinuous compression molding machine.

As depicted, inclined sleeve 2100 and a continuous compression moldingmachine may form composite material 2102 into U-shapedcross-sectional-shape 2128. U-shaped cross-sectional shape 2128 may alsobe referred to as a C-shaped cross-sectional shape or C channel.However, in other illustrative examples, inclined sleeve 2100 may beused alone or in conjunction with other tools or sleeves to formcomposite material 2102 in a different cross-sectional shape thanU-shaped cross-sectional shape. For example, inclined sleeve 2100 may beused alone or in conjunction with other tools or sleeves to formcomposite material 2102 in a cross-sectional shape selected from atrapezoidal shape, a triangular shape, a J shape, an I shape, a Z shapeor any other desirable cross-sectional shape.

As inclined sleeve 2100 is moved in direction 2118, a shim (notdepicted) may be placed within cavity 2114. A shim may be a piece ofmaterial placed within cavity 2114 such that any inconsistencies infirst inclined surface 2108, second inclined surface 2110, orsubstantially planar surface 2112 may not affect application of pressureto composite material 2102. In some illustrative examples,inconsistencies in any of first inclined surface 2108, second inclinedsurface 2110, or inclined surfaces of an inclined die may cause theinclined die to engage inclined sleeve 2100 in an undesirable manner.Specifically, inconsistencies in any of first inclined surface 2108,second inclined surface 2110, or inclined surfaces of an inclined diemay cause the inclined die to not fully move downward into inclinedsleeve 2100. Inconsistencies may include bumps, dips, differinginclines, or other types of surface inconsistencies. When the inclineddie does not move completely downward into inclined sleeve 2100, theinclined die may not contact substantially planar surface 2112 or mayonly partially contact substantially planar surface 2112. When theinclined die does not move completely downward into inclined sleeve2100, application of pressure to composite material 2102 may beaffected. For example, application of pressure to composite material2102 may not be uniform. As a result, a shim may be positioned such thatan inclined die may contact the shim and inclined sleeve 2100 to imparta substantially uniform pressure to composite material 2102. Further, ashim may be positioned such that inconsistencies in either substantiallyplanar surface 2112 or a substantially planar surface of an inclined diemay not affect application of pressure to composite material 2102.

The shim may be positioned between the first face of an inclined die andfirst face 2104 of inclined sleeve 2100. The shim may be in contact withat least a portion of substantially planar surface 2112. The shim may bepositioned between a second substantially planar surface of an inclineddie and substantially planar surface 2112 of inclined sleeve 2100. Theshim may contact at least a portion of a second substantially planarsurface of an inclined die and at least a portion of substantiallyplanar surface 2112 of inclined sleeve 2100.

A shim may be formed from a rigid material. A rigid material may bemachined or otherwise formed to a desirable shape for the shim. A shimmay be formed from a malleable material. When a shim is formed of amalleable material, the shim may “self-form” to a desirable shapebetween an inclined die and inclined sleeve 1900. The shim could have aconstant thickness or a varying thickness as desirable.

Turning now to FIG. 22, an illustration of another example of anisometric view of an inclined sleeve, tooling, and composite material isdepicted in accordance with an illustrative embodiment. As depicted,inclined sleeve 2200 may be used as a U-shaped tooling channel 86 ofFIG. 1. Inclined sleeve 2200 may be used in a continuous compressionmolding machine to shape composite material 2202. Composite material2202 may be formed into a U-shaped cross-sectional shape using inclinedsleeve 2200.

A U-shaped cross-sectional shape may also be referred to as a C-shapedcross-sectional shape or C channel. However, in other illustrativeexamples, inclined sleeve 2200 may be used alone or in conjunction withother tools or sleeves to form composite material 2102 in a differentcross-sectional shape than U-shaped cross-sectional shape. For example,inclined sleeve 2200 may be used alone or in conjunction with othertools or sleeves to form composite material 2202 in a cross-sectionalshape selected from a trapezoidal shape, a triangular shape, a J shape,an I shape, a Z shape or any other desirable cross-sectional shape.

Inclined sleeve 2200 may have first face 2204 and second face 2206.Second face 2206 may have features to mold composite material 2202. Asdepicted, second face 2206 has feature 2207 to mold composite material2202. As can be seen from FIG. 22, feature 2207 may contact ply addition2209 of composite material 2202. Feature 2207 may allow for about equalpressure to be exerted on all of composite material 2202, including plyaddition 2209, by a continuous compression molding machine. As depicted,feature 2207 may substantially mirror ply addition 2209. In other words,feature 2207 may be substantially the inverse of ply addition 2209. Insome illustrative examples, feature 2207 may not substantially mirrorply addition 2209. In some illustrative examples, feature 2207 may bedifferent than the shape of composite material 2202. By feature 2207being different than the shape of composite material 2202, inclinedsleeve 2200 may mold composite material 2202.

First face 2204 may have first inclined surface 2208, second inclinedsurface 2210, and substantially planar surface 2212. As depicted,substantially planar surface 2212 may be positioned between firstinclined surface 2208 and second inclined surface 2210.

First face 2204 may form cavity 2214. Cavity 2214 may receive aninclined die (not depicted). As depicted, composite material 2202 may bepositioned between inclined sleeve 2200 and base 2216. Inclined sleeve2200, composite material 2202, and base 2216 may all move in direction2218 towards a continuous compression molding machine (not depicted). Asinclined sleeve 2200, composite material 2202, and base 2216 may allmove in direction 2218, composite material 2202 may be formed to contactside 2220 and side 2222 of second face 2206. Specifically, surface 2223may be formed to second face 2206. Side tooling member 2224 and sidetooling member 2226 may be positioned relative to composite material2202 and inclined sleeve 2200. Each of inclined sleeve 2200, compositematerial 2202, base 2216, side tooling member 2224, and side toolingmember 2226 may move in direction 2218 towards an inclined die of thecontinuous compression molding machine.

As inclined sleeve 2200 is moved in direction 2218, a shim may be placedwithin cavity 2214. A shim may be a piece of material placed withincavity 2214 such that any inconsistencies in substantially planarsurface 2212 may not affect application of pressure to compositematerial 2202.

A shim may be formed from a rigid material. A rigid material may bemachined or otherwise formed to a desirable shape for the shim. A shimmay be formed from a malleable material. When a shim is formed of amalleable material, the shim may “self-form” to a desirable shapebetween an inclined die and inclined sleeve 2200. The shim could have aconstant thickness or a varying thickness as desirable.

Although composite material 2202 is depicted as substantially coveringsecond face 2206, in some examples, composite material 2202 may notsubstantially cover second face 2206. For example, composite material2202 may not contact side 2220. In some illustrative examples, compositematerial 2202 may not contact either side 2220 or side 2222. In theseillustrative examples, composite material 2202 may only be positionedbetween inclined sleeve 2200 and base 2216.

Turning now to FIG. 23, an illustration of a further example of anisometric view of an inclined sleeve, tooling, and composite material isdepicted in accordance with an illustrative embodiment. Assembly 2300includes inclined sleeve 2301. As depicted, inclined sleeve 2301 may beused as a U-shaped tooling channel 86 of FIG. 1. In this illustrativeexample, inclined sleeve 2301 is used along with a bottom U-shapedtooling channel 2302. U-shaped tooling channel 2302 does not haveinclined surfaces. Inclined sleeve 2301 and U-shaped tooling channel2302 may be used to form an I-shaped composite part.

Inclined sleeve 2301 may be used in a continuous compression moldingmachine to shape composite material 2303. Composite material 2303 may beformed into a U-shape using inclined sleeve 2301. Composite material2304 may be formed into a U-shape using U-shaped tooling channel 2302.Composite filler 2306, composite ply 2308, composite filler 2310, andcomposite ply 2312 may be positioned relative to composite material 2303and composite material 2304 to form an I-shaped composite part.

Inclined sleeve 2301 may have first face 2314 and second face 2316.Second face 2316 may have features to mold composite material 2303. Asdepicted, second face 2316 has feature 2317 to mold composite material2303. As can be seen from FIG. 23, feature 2317 may contact ply addition2318 of composite material 2303. Feature 2317 may allow for plydrop-offs or ramp-ups. Feature 2317 may allow for about equal pressureto be exerted on all of composite material 2303, including ply addition2318, by a continuous compression molding machine.

As depicted, feature 2317 may substantially mirror ply addition 2318. Inother words, feature 2317 may be substantially the inverse of plyaddition 2318. In some illustrative examples, feature 2317 may notsubstantially mirror ply addition 2318. In some illustrative examples,feature 2317 may be different than the shape of composite material 2303.By feature 2317 being different than the shape of composite material2303, inclined sleeve 2301 may mold composite material 2303.

First face 2314 may have first inclined surface 2320, second inclinedsurface 2322, and substantially planar surface 2324. As depicted,substantially planar surface 2324 may be positioned between firstinclined surface 2320 and second inclined surface 2322.

First face 2314 may form cavity 2326. Cavity 2326 may receive aninclined die (not depicted). As depicted, composite material 2303 may bepositioned between inclined sleeve 2301 and composite material 2304.

As inclined sleeve 2301 and composite material 2303 move in direction2318, composite material 2303 may be formed to contact side 2328 andside 2330 of second face 2316. Specifically, surface 2323 may be formedto second face 2316. As U-shaped tooling channel 2302 and compositematerial 2304 move in direction 2318, composite material 2304 may beformed to contact side 2328 and side 2330 of face 2332 of U-shapedtooling channel 2302.

As inclined sleeve 2301, U-shaped tooling channel 2302, compositematerial 2303 and composite material 2304 are moved in direction 2318,composite filler 2306 and composite filler 2310 may be positionedrelative to composite material 2303 and composite material 2304.Specifically, composite filler 2306 and composite filler 2310 may bepositioned within gaps at the interface of composite material 2303 andcomposite material 2304. Composite filler 2306 and composite filler 2310may each also be referred to as a composite noodle or simply a noodle.

Further, as inclined sleeve 2301, U-shaped tooling channel 2302,composite material 2303, composite material 2304, composite filler 2306,and composite filler 2310 are moved in direction 2318, composite ply2308 and composite ply 2312 may be positioned relative to compositematerial 2303 and composite material 2304. Specifically, composite ply2308 may be positioned over portions of composite material 2303,portions of composite material 2304, and composite filler 2306.Composite ply 2312 may be positioned over portions of composite material2303, portions of composite material 2304, and composite filler 2306.

Inclined sleeve 2301, U-shaped tooling channel 2302, composite material2303, composite material 2304, composite filler 2306, composite ply2308, composite filler 2310, and composite ply 2312 may all move indirection 2318 towards a continuous compression molding machine (notdepicted). As inclined sleeve 2301, U-shaped tooling channel 2302,composite material 2303, composite material 2304, composite filler 2306,composite ply 2308, composite filler 2310, and composite ply 2312 movein direction 2318 towards a continuous compression molding machine, sidetooling member 2334 and side tooling member 2336 may be positionedrelative to composite ply 2308 and composite ply 2312, respectively. Ina continuous compression molding machine, an inclined die may impactinclined sleeve 2301. In a continuous compression molding machine, arespective die may impact each of U-shaped tooling channel 2302, sidetooling member 2334, and side tooling member 2336.

Turning now to FIG. 24, an illustration of another example of anisometric view of an inclined sleeve, tooling, and composite material isdepicted in accordance with an illustrative embodiment. FIG. 24 is aview of assembly 2300 with inclined sleeve 2400 replacing U-shapedtooling channel 2302. In this illustrative example, a second inclineddie may impact inclined sleeve 2400 in a continuous compression moldingmachine.

Turning now to FIG. 25, an illustration of a cross-sectional view of aninclined sleeve in a continuous compression molding machine is depictedin accordance with an illustrative embodiment. Continuous compressionmolding environment 2500 may be a simplified view within a continuouscompression molding machine. View 2501 may be of an inclined sleevewithin a continuous compression molding machine, such as inclined sleeve2100 of FIG. 21 in cross-section 25-25 from direction 2130. Continuouscompression molding environment 2500 includes inclined die 2502,inclined sleeve 2504, side tooling member 2506, base 2508, side toolingmember 2510, shim 2512, and composite material 2514. Composite material2514 may take the form of a multiple ply stack. A multiple ply stack mayhave a number of ply orientations. As used herein, a number of itemsmeans one or more items. For example, a multiple ply stack may have oneor more ply orientations.

As depicted, inclined die 2502 may engage inclined sleeve 2504. Inclineddie 2502 may also be referred to as a continuous compression moldingdie. Inclined sleeve 2504 may have first face 2515 and second face 2517.Second face 2517 may have features to mold composite material 2514.First face 2515 may have first inclined surface 2518, second inclinedsurface 2520, and substantially planar surface 2522.

Substantially planar surface 2522 may be positioned between firstinclined surface 2518 and second inclined surface 2520. First inclinedsurface 2518 may substantially conform to a portion of inclined die2502. Second inclined surface 2520 may substantially conform to a secondportion of inclined die 2502. First face 2515 forms cavity 2523 that mayreceive inclined die 2502.

Inclined die 2502 may have third inclined surface 2524, fourth inclinedsurface 2526, and substantially planar surface 2528. Third inclinedsurface 2524, fourth inclined surface 2526, and substantially planarsurface 2528 may form face 2529. Third inclined surface 2524 may engagefirst inclined surface 2518. Fourth inclined surface 2526 may engagesecond inclined surface 2520. In some illustrative examples,inconsistencies which are out of tolerance in any of first inclinedsurface 2518, second inclined surface 2520, third inclined surface 2524,or fourth inclined surface 2526 may cause inclined die 2502 to engageinclined sleeve 2504 in an undesirable manner. Inconsistencies which areout of tolerance may include bumps, dips, differing inclines, or othertypes of surface inconsistencies. Specifically, inconsistencies in anyof first inclined surface 2518, second inclined surface 2520, thirdinclined surface 2524, or fourth inclined surface 2526 may causeinclined die 2502 to not fully move downward into inclined sleeve 2504.When inclined die 2502 does not move completely downward into inclinedsleeve 2504, inclined die 2502 may not contact substantially planarsurface 2522 or may only partially contact substantially planar surface2522. When inclined die 2502 does not move completely downward intoinclined sleeve 2504, application of pressure to composite material 2102may be affected. For example, application of pressure to compositematerial 2514 may not be uniform. Because inconsistencies in any offirst inclined surface 2518, second inclined surface 2520, thirdinclined surface 2524, or fourth inclined surface 2526 may causeinclined die 2502 to not contact substantially planar surface 2522 oronly partially contact substantially planar surface 2522, it may be saidthat first inclined surface 2518, second inclined surface 2520, thirdinclined surface 2524, or fourth inclined surface 2526 may concentrateinconsistencies between substantially planar surface 2522 andsubstantially planar surface 2528. In other words, by third inclinedsurface 2524 engaging first inclined surface 2518 and fourth inclinedsurface 2526 engaging second inclined surface 2520, inconsistencies maybe concentrated between substantially planar surface 2522 andsubstantially planar surface 2528.

By concentrating inconsistencies between substantially planar surface2522 and substantially planar surface 2528, shim 2512, a single shim,may be used to compensate for inconsistencies in any of the surfaces. Inother words, shim 2512 may compensate for inconsistencies in any offirst inclined surface 2518, second inclined surface 2520, thirdinclined surface 2524, fourth inclined surface 2526, substantiallyplanar surface 2522, or substantially planar surface 2528. As a result,shim 2512 may be positioned such that inclined die 2502 may contact shim2512 and inclined sleeve 2504 to impart a substantially uniform pressureto composite material 2514. Further, shim 2512 may be positioned suchthat inconsistencies in either substantially planar surface 2112 orsubstantially planar surface 2528 may not affect application of pressureto composite material 2514.

Shim 2512 may be used to provide substantially even pressure tocomposite material 2514. Shim 2512 may be a piece of material placedwithin cavity 2523 such that inconsistencies which are out of tolerancemay not affect application of pressure to composite material 2514. Shim2512 may be positioned between inclined sleeve 2504 and inclined die2502. Shim 2512 may be positioned between first face 2529 of an inclineddie 2502 and first face 2515 of inclined sleeve 2504.

Shim 2512 may be in contact with at least a portion of substantiallyplanar surface 2522. Shim 2512 may be positioned between secondsubstantially planar surface 2528 of inclined die 2502 and substantiallyplanar surface 2522 of inclined sleeve 2504. Shim 2512 may contact atleast a portion of second substantially planar surface 2528 of inclineddie 2502 and at least a portion of substantially planar surface 2522 ofinclined sleeve 2504.

Shim 2512 may be formed from a rigid material. A rigid material may bemachined or otherwise formed to a desirable shape for shim 2512. Shim2512 may be formed from a malleable material. When shim 2512 is formedof a malleable material, shim 2512 may “self-form” to a desirable shapebetween inclined die 2502 and inclined sleeve 2504. Shim 2512 could havea constant thickness or a varying thickness as desirable.

Further, shape of inclined die 2502 may be self-locating. Specifically,third inclined surface 2524 and fourth inclined surface 2526 may allowinclined die 2502 to be self-locating. When inclined die 2502 isself-locating, third inclined surface 2524 and fourth inclined surface2526 may allow inclined die 2502 to reach desired position 2527.Specifically, when inclined die 2502 is self-locating, when inclined die2502 is moved towards inclined sleeve 2504, third inclined surface 2524and fourth inclined surface 2526 may guide inclined die 2502 to moveuntil inclined die 2502 is in desired position 2527.

As depicted, inclined sleeve 2504 may move into the page throughcontinuous compression molding environment 2500. In these illustrativeexamples, inclined sleeve 2504 may stay in substantially the samelocation relative to composite material 2514 during forming of compositematerial 2514. In other words, both inclined sleeve 2504 and compositematerial 2514 may move into the page incrementally during forming ofcomposite material 2514.

During forming of composite material 2514, side tooling member 2506 maycontact composite material 2514. Further, during forming of compositematerial 2514, side tooling member 2510 may contact composite material2514. In some illustrative examples, side tooling member 2506 and sidetooling member 2510 may remain in contact with composite material 2514as composite material 2514 moves through the continuous compressionmolding machine. In these illustrative examples, side tooling member2506 and side tooling member 2510 may be impacted by a respective die ofcontinuous compression molding machine.

In some illustrative examples, side tooling member 2506 may move indirection 2530 to contact composite material 2514 each time pressure isapplied to composite material 2514 as composite material 2514 moves intothe page through the continuous compression molding machine. In otherwords, side tooling member 2506 may move in direction 2530 to contactcomposite material 2514 and then be retracted in direction 2532 to formeach increment of composite material 2514 in continuous compressionmolding machine.

Side tooling member 2510 may move in direction 2532 to contact compositematerial 2514 each time pressure is applied to composite material 2514as composite material 2514 moves into the page through the continuouscompression molding machine. In other words, side tooling member 2510may move in direction 2532 to contact composite material 2514 and thenbe retracted in direction 2530 to form each increment of compositematerial 2514 in continuous compression molding machine.

Third inclined surface 2524 and first inclined surface 2518 each haveangle 2534. Angle 2534 may be selected based on at least one ofmanufacturing tolerances, material properties of the material ofinclined sleeve 2504, or other desirable information. For example, angle2534 may be selected such that undesirable heat transfer properties dueto the thickness of material of inclined sleeve 2504 are reduced. Forexample, reducing angle 2534 may increase the thickness of material ofinclined sleeve 2504. As used herein, reducing angle 2534 may causeangle 2534 to approach 0 degrees. With increased thickness of inclinedsleeve 2504, inclined sleeve 2504 may take longer to heat and cool. As aresult, heat transfer properties may become more undesirable as angle2534 decreases. As another example, angle 2534 may be selected such thatthe weight of inclined sleeve 2504 is not undesirably high. For example,reducing angle 2534 may increase the thickness of material of inclinedsleeve 2504. Increasing the thickness of the material of inclined sleeve2504 may also increase the weight of inclined sleeve 2504.

First face 2529 of inclined die 2502 may have radius 2536. First face2515 of inclined sleeve 2504 may have radius 2538. As depicted, radius2536 may be larger than radius 2538. When radius 2536 is larger thanradius 2538, inclined die 2502 may not be connected to inclined sleeve2504 without a number of connectors. In other words, the shape ofinclined die 2502 may not cause a binding condition with inclined sleeve2504 when radius 2536 is larger than radius 2538.

Continuous compression molding environment 2500 may be a simplified viewwithin a continuous compression molding machine. Continuous compressionmolding environment 2500 is simplified for description of inclinedsleeve 2504. A continuous compression molding machine may include othercomponents not shown within FIG. 25.

Turning now to FIG. 26, an illustration of a front view of an inclinedsleeve in a continuous compression molding machine is depicted inaccordance with an illustrative embodiment. Continuous compressionmolding environment 2600 may be a simplified view within a continuouscompression molding machine.

As depicted, continuous compression molding environment 2600 includesthe components of continuous compression molding environment 2500.However, as depicted, inclined sleeve 2504 is secured to inclined die2502.

As depicted, connector 2602 and connector 2604 may be two of a number ofconnectors that may hold inclined sleeve 2504 in place relative toinclined die 2502. In this illustrative example, composite materialmoves into the page to travel through the continuous compression moldingmachine. In other words, inclined sleeve 2504 may be installed intocontinuous compression molding machine by connecting inclined sleeve2504 to inclined die 2502 prior to forming composite material 2514.Inclined sleeve 2504 may stay in substantially the same locationrelative to inclined die 2502 during forming of composite material 2514.

Turning now to FIG. 27, an illustration of an isometric view of aninclined sleeve is depicted in accordance with an illustrativeembodiment. Inclined sleeve 2700 may also be referred to as a toolingchannel. Inclined sleeve 2700 may be used with associated toolingsimilar to U-shaped tooling channels 86 of FIG. 1.

Inclined sleeve 2700 may have first face 2702 and second face 2704.Second face 2704 may have features to mold a composite material. Firstface 2702 may have first inclined surface 2706, surface 2708, andsubstantially planar surface 2710. As depicted, substantially planarsurface 2710 may be positioned between first inclined surface 2706 andsurface 2708.

First face 2702 may form cavity 2712. Cavity 2712 may receive a die (notdepicted). The die may have its own respective inclined surface. Firstinclined surface 2706 may substantially conform to a portion of theinclined die.

To form a composite material, inclined sleeve 2700 may be positionedbetween the die and the composite material. In these illustrativeexamples, first face 2702 may engage the die while second face 2704 maycontact the composite material.

Turning now to FIG. 28, an illustration of a front view of an inclinedsleeve is depicted in accordance with an illustrative embodiment. View2800 may be a view of inclined sleeve 2700 from direction 28-28 of FIG.27. First inclined surface 2706 may be positioned at angle 2802 relativeto substantially planar surface 2710. Surface 2708 may be positioned atangle 2804 relative to substantially planar surface 2710. As depicted,angle 2802 and angle 2804 are different from each other. As depicted,angle 2804 is about 90 degrees relative to substantially planar surface2710.

As depicted, angle 2802 may be about 75 degrees. However, angle 2802 maybe any desirable angle within greater than about 0 degrees and less thanabout 90 degrees. Angle 2802 may be selected based on at least one of anangle of an inclined surface of an inclined die, manufacturingtolerances, material properties of the material of inclined sleeve 2700,or other desirable information. For example, angle 2802 may be selectedsuch that undesirable heat transfer properties due to the thickness ofmaterial of inclined sleeve 2700 are reduced. For example, reducingangle 2802 may increase the thickness of material of inclined sleeve2700. As used herein, reducing angle 2802 may cause angle 2802 toapproach 0 degrees. With increased thickness of inclined sleeve 2700,inclined sleeve 2700 may take longer to heat and cool. As a result, heattransfer properties may become more undesirable as angle 2802 decreases.

As another example, angle 2802 may be selected such that the weight ofinclined sleeve 2700 is not undesirably high. For example, reducingangle 2802 may increase the thickness of material of inclined sleeve2700. Increasing the thickness of the material of inclined sleeve 2700may also increase the weight of inclined sleeve 2700.

The illustrations of inclined sleeves depictions, composite materialdepictions, and inclined die depictions in FIGS. 19-28 are not meant toimply physical or architectural limitations to the manner in which anillustrative embodiment may be implemented. Other components in additionto or in place of the ones illustrated may be used. Some components maybe unnecessary. For example, angle 2534 may be greater than or less than75 degrees. Angle 2534 may be any desirable angle greater than about 0degrees and less than about 90 degrees. As a further example, angle 2002may be different than angle 2004.

As yet a further example, one of angle 2002 and angle 2004 may be about90 degrees. As a result, inclined sleeve 1900 may only have one inclinedsurface rather than two inclined surfaces. In this example, one of firstinclined surface 1906 and second inclined surface 1908 may not bereferred to as an “inclined” surface. For example, when angle 2004 isabout 90 degrees, item 1908 may instead be referred to as simply asurface. As another example, when angle 2002 is about 90 degrees, item1906 may instead be referred to as simply a surface.

As another example, rather than connector 2602 and connector 2604,inclined sleeve 2504 may have a front face and a back face such thatinclined die 2502 securely fits within first face 2515, contacting thefront face and the back face. In this example, the snug fit of inclineddie 2502 within inclined sleeve 2504 may hold inclined sleeve 2504 inplace. Further, attachment mechanisms such as screws, bolts, pins, orother desirable attachment mechanisms may be inserted into inclined die2502 and inclined sleeve 2504 to further secure inclined sleeve 2504 toinclined die 2502.

Turning now to FIG. 29, an illustration of a flowchart of a process forforming a composite part is depicted in accordance with an illustrativeembodiment. Process 2900 may use an inclined sleeve such as inclinedsleeve 1900 of FIGS. 19 and 20, inclined sleeve 2200 of FIG. 22, orinclined sleeve 2700 of FIGS. 27 and 28. Process 2900 may be used toform a composite part such thermoplastic composite laminate floor beam20 of FIG. 1.

Process 2900 may begin by placing a multiple ply stack 2514 relative toa inclined sleeve 2504 such that at least a portion of the multiple plystack 2514 contacts at least a portion of a first face 2517 of theinclined sleeve 2504 (operation 2902). The multiple ply stack may have anumber of features that change a thickness of the multiple ply stacksuch as ramp ups, ramp downs, ply additions, ply subtractions, or otherdesirable features. In some illustrative examples, only a fraction of afirst surface of the multiple ply stack may first contact a portion ofthe first face at first. In these illustrative examples, the remainderof the first surface of the multiple ply stack may be pressed againstthe first face of the inclined sleeve by other associated tooling.

Process 2900 may also feed the multiple ply stack 2514 and the inclinedsleeve 2504 into a continuous compression molding machine (operation2904). The continuous compression molding machine may have a number ofinclined dies. An inclined die of the number of inclined dies may alsobe referred to as a continuous compression molding die.

Process 2900 may also lower an inclined die 2502 of the continuouscompression molding machine to engage a second face 2515 of the inclinedsleeve 2504 (operation 2906). Afterwards, process 2900 terminates.

Prior to lowering the inclined die, the second face of the inclinedsleeve may be in engageable alignment with the inclined die. When theinclined sleeve is in engageable alignment with the inclined die, theinclined die may be lowered to contact the second face of the inclinedsleeve.

In some illustrative examples, lowering the inclined die of thecontinuous compression molding machine to engage a second face of theinclined sleeve comprises lowering the inclined die such that a firstinclined surface and a second inclined surface of the inclined diecontacts a third inclined surface and a fourth inclined surface of theinclined sleeve. In these illustrative examples, the first inclinedsurface and the third inclined surface may have the same angle. In theseillustrative examples, the second inclined surface and the fourthinclined surface may have the same angle. In some illustrative examples,each of the first inclined surface, the second inclined surface, thethird inclined surface, and the fourth inclined surface may have thesame angle. In some illustrative examples, the angle of the firstinclined surface and the third inclined surface may be different thanthe angle of the second inclined surface and the fourth inclinedsurface.

Turning now to FIG. 30, an illustration of a flowchart of a process forforming a composite part is depicted in accordance with an illustrativeembodiment. Process 3000 may use an inclined sleeve such as inclinedsleeve 1900 of FIGS. 19 and 20, inclined sleeve 2200 of FIG. 22, orinclined sleeve 2700 of FIGS. 27 and 28. Process 3000 may be used toform a composite part such thermoplastic composite laminate floor beam20 of FIG. 1.

Process 3000 may begin by installing an inclined sleeve 2504 over ainclined die 2502, the inclined sleeve 2504 having a first inclinedsurface 2518, a second inclined surface 2520, and a substantially planarsurface 2522 between the first inclined surface 2518 and the secondinclined surface 2520, each of the first inclined surface 2518 and thesecond inclined surface 2520 contacting a respective inclined surface ofthe inclined die 2502 (operation 3002). In some illustrative examples,the cross-section of the inclined sleeve may be constant. In someillustrative examples, the cross-section of the inclined sleeve may varyacross the length of the inclined sleeve. For example, the cross-sectionof the inclined sleeve may vary over its length if the incline sleevehas surface features which correspond to a number of ply additions, plydrops, ramp ups, ramp downs, or other features of a composite part.

Process 3000 may then place at least one shim 2512 between the inclinedsleeve 2504 and the inclined die 2502 (operation 3004). The shim mayallow for even pressure to be imparted to a composite material by theinclined die and the inclined sleeve. The shim may compensate formanufacturing tolerances or other inconsistencies in the inclinedsleeve.

Process 3000 may then secure the inclined sleeve 2504 to the inclineddie 2502 (operation 3006). By securing the inclined sleeve to theinclined die, the shape of a forming surface for a composite materialmay be changed. By securing the inclined sleeve to the inclined die, acomposite material may be fed through a continuous compression moldingmachine and formed by the inclined sleeve. The inclined sleeve mayremain in substantially the location relative to the inclined die.

The flowcharts and block diagrams in the different depicted embodimentsillustrate the architecture, functionality, and operation of somepossible implementations of apparatuses and methods in an illustrativeembodiment. In this regard, each block in the flowcharts or blockdiagrams may represent at least one of a module, a segment, a function,or a portion of an operation or step.

In some alternative implementations of an illustrative embodiment, thefunction or functions noted in the blocks may occur out of the ordernoted in the figures. For example, in some cases, two blocks shown insuccession may be executed substantially concurrently, or the blocks maysometimes be performed in the reverse order, depending upon thefunctionality involved. Also, other blocks may be added in addition tothe illustrated blocks in a flowchart or block diagram.

Turning now to FIG. 31, an illustration of an aircraft is depicted inaccordance with an illustrative embodiment. In this illustrativeexample, aircraft 3100 has wing 3102 and wing 3104 attached to body3106. Aircraft 3100 includes engine 3108 attached to wing 3102 andengine 3110 attached to wing 3104.

Body 3106 has tail section 3112. Horizontal stabilizer 3114, horizontalstabilizer 3116, and vertical stabilizer 3118 are attached to tailsection 3112 of body 3106.

Aircraft 3100 is an example of an aircraft in which a composite partformed using an inclined sleeve may be implemented in accordance with anillustrative embodiment. For example, stiffeners 3120 contactingcomposite skin 3122 of aircraft 3100 may be formed using an inclinedsleeve. FIG. 31 depicts an exposed view of stiffeners 3120.

This illustration of aircraft 3100 is provided for purposes ofillustrating one environment in which the different illustrativeembodiments may be implemented. The illustration of aircraft 3100 inFIG. 31 is not meant to imply architectural limitations to the manner inwhich different illustrative embodiments may be implemented. Forexample, aircraft 3100 is shown as a commercial passenger aircraft. Thedifferent illustrative embodiments may be applied to other types ofaircraft, such as private passenger aircraft, a rotorcraft, and othersuitable types of aircraft.

The illustrative embodiments of the disclosure may be described in thecontext of aircraft manufacturing and service method 3200 as shown inFIG. 32 and aircraft 3320 as shown in FIG. 33. Turning first to FIG. 32,an illustration of a block diagram of an aircraft manufacturing andservice method is depicted in accordance with an illustrativeembodiment. During pre-production, aircraft manufacturing and servicemethod 3200 may include specification and design 3202 of aircraft 3320in FIG. 33 and material procurement 3204.

During production, component and subassembly manufacturing 3206 andsystem integration 3208 of aircraft 3320 in FIG. 33 takes place.Thereafter, aircraft 3320 in FIG. 33 may go through certification anddelivery 3210 in order to be placed in service 3212. While in service3212 by a customer, aircraft 3320 in FIG. 33 is scheduled for routinemaintenance and service 3214, which may include modification,reconfiguration, refurbishment, and other maintenance or service.

Each of the processes of aircraft manufacturing and service method 3200may be performed or carried out by a system integrator, a third party,and/or an operator. In these examples, the operator may be a customer.For the purposes of this description, a system integrator may include,without limitation, any number of aircraft manufacturers andmajor-system subcontractors; a third party may include, withoutlimitation, any number of vendors, subcontractors, and suppliers; and anoperator may be an airline, a leasing company, a military entity, aservice organization, and so on.

With reference now to FIG. 33, an illustration of a block diagram of anaircraft is depicted in which an illustrative embodiment may beimplemented. In this example, aircraft 3320 is produced by aircraftmanufacturing and service method 3200 in FIG. 32 and may includeairframe 3322 with plurality of systems 3324 and interior 3326. Examplesof systems 3324 include one or more of propulsion system 3328,electrical system 3310, hydraulic system 3312, and environmental system3314. Any number of other systems may be included. Although an aerospaceexample is shown, different illustrative embodiments may be applied toother industries, such as the automotive industry. The apparatuses andmethods embodied herein may be employed during at least one of thestages of aircraft manufacturing and service method 3200 in FIG. 32.

One or more illustrative embodiments may be used during component andsubassembly manufacturing 3206. For example, inclined sleeve 1900 may beused to form a composite structure during component and subassemblymanufacturing 3206. Further, a composite structure formed by inclinedsleeve 1900 may also be used to replace a composite filler duringmaintenance and service 3214.

The illustrative embodiments provide a system and method for forming acomposite part using an inclined sleeve. The inclined surfaces of theinclined sleeve engage inclined surfaces of an inclined die. By havinginclined surfaces, inconsistencies due to manufacturing tolerances orother inconsistencies of the inclined sleeve or the inclined die may notinfluence the application of pressure to a composite material.Specifically, by having inclined surfaces, inconsistencies may beconcentrated between a substantially planar surface of the inclined dieand a substantially planar surface of the inclined sleeve. A shim may beplaced between a substantially planar surface of the inclined die and asubstantially planar surface of the inclined sleeve to compensate forthese inconsistencies. Further, the respective inclined surfaces maycause the inclined die to be self-locating.

The inclined sleeve and inclined die may reduce product inconsistenciessuch as porosity in resulting composite parts following forming. Bysupplying even pressure to a composite material, resulting compositeparts may have desirable quality.

The description of the different illustrative embodiments has beenpresented for purposes of illustration and description, and is notintended to be exhaustive or limited to the embodiments in the formdisclosed. Many modifications and variations will be apparent to thoseof ordinary skill in the art. Further, different illustrativeembodiments may provide different features as compared to otherillustrative embodiments. The embodiment or embodiments selected arechosen and described in order to best explain the principles of theembodiments, the practical application, and to enable others of ordinaryskill in the art to understand the disclosure for various embodimentswith various modifications as are suited to the particular usecontemplated.

What is claimed is:
 1. An apparatus comprising: a sleeve that molds acomposite material, the sleeve having a first face and a second face,the second face having features to mold the composite material, thefirst face comprising: a first inclined surface having an angle lessthan about 90 degrees and greater than about 0 degrees.
 2. The apparatusof claim 1, the first face further comprising: a second inclined surfacehaving an angle less than about 90 degrees and greater than about 0degrees.
 3. The apparatus of claim 2, wherein the first inclined surfacesubstantially conforms to a portion of an inclined die, and wherein thesecond inclined surface substantially conforms to a second portion ofthe inclined die.
 4. The apparatus of claim 3 further comprising: asubstantially planar surface positioned between the first inclinedsurface and the second inclined surface.
 5. The apparatus of claim 4further comprising: a shim in contact with at least a portion of thesubstantially planar surface.
 6. The apparatus of claim 3 furthercomprising: the inclined die having a third inclined surface, a fourthinclined surface, and a second substantially planar surface positionedbetween the third inclined surface and the fourth inclined surface. 7.The apparatus of claim 6 further comprising: a number of connectorsholding the sleeve in place relative to the inclined die.
 8. Theapparatus of claim 1, wherein the first face forms a cavity thatreceives an inclined die.
 9. An apparatus comprising: an inclined diehaving a first face; an inclined sleeve having a second face inengageable alignment with the inclined die; and a shim positionedbetween the first face of the inclined die and the second face of theinclined sleeve.
 10. The apparatus of claim 9, wherein the second faceof the inclined sleeve comprises a first inclined surface having anangle less than about 90 degrees and greater than about 0 degrees. 11.The apparatus of claim 10, wherein the shim is positioned between asubstantially planar surface of the second face of the inclined sleeveand a second substantially planar surface of the first face of theinclined die.
 12. The apparatus of claim 10, wherein the first face ofthe inclined die comprises a second inclined surface having an angleless than about 90 degrees and greater than about 0 degrees.
 13. Theapparatus of claim 12, wherein at least a portion of the second inclinedsurface engages at least a portion of the first inclined surface. 14.The apparatus of claim 9, wherein the shim contacts at least a portionof a substantially planar surface of the second face of the inclinedsleeve and at least a portion of a second substantially planar surfaceof the first face of the inclined die.
 15. The apparatus of claim 9further comprising: a number of connectors holding the inclined sleevein place relative to the inclined die.
 16. An apparatus comprising: asleeve located between a continuous compression molding die and acomposite charge, the sleeve having a first face that forms a cavity,the first face comprising: a first inclined surface having an angle lessthan about 90 degrees and greater than about 0 degrees which conforms toa second inclined surface of the continuous compression molding die. 17.The apparatus of claim 16, the first face further comprising: a thirdinclined surface having an angle less than about 90 degrees and greaterthan about 0 degrees.
 18. The apparatus of claim 17 further comprising:the continuous compression molding die, the continuous compressionmolding die comprising the second inclined surface conforming to thefirst inclined surface, a fourth inclined surface conforming to thethird inclined surface, and a substantially planar surface between therespective inclined surfaces.
 19. The apparatus of claim 18 furthercomprising: a shim located between the sleeve and the continuouscompression molding die.
 20. The apparatus of claim 19 furthercomprising: a number of connectors holding the sleeve in place relativeto the continuous compression molding die.
 21. A method comprising:placing a multiple ply stack relative to an inclined sleeve such that atleast a portion of the multiple ply stack contacts at least a portion ofa first face of the inclined sleeve; feeding the multiple ply stack andthe inclined sleeve into a continuous compression molding machine; andlowering an inclined die of the continuous compression molding machineto engage a second face of the inclined sleeve.
 22. The method of claim21, wherein lowering the inclined die of the continuous compressionmolding machine to engage the second face of the inclined sleevecomprises lowering the inclined die such that a first inclined surfaceand a second inclined surface of the inclined die contacts a thirdinclined surface and a fourth inclined surface of the inclined sleeve.23. A method comprising: installing an inclined sleeve over an inclineddie such that a first inclined surface of the inclined sleeve engages asecond inclined surface of the inclined die, the first inclined surfacehaving an angle less than about 90 degrees and greater than about 0degrees; placing at least one shim between the inclined sleeve and theinclined die; and securing the inclined sleeve to the inclined die. 24.The method of claim 23, wherein placing the at least one shim betweenthe inclined sleeve and the inclined die comprises placing the at leastone shim between a substantially planar surface of the inclined sleeveand a second substantially planar surface of the inclined die.